Method and System for Forming Masks

ABSTRACT

A method and apparatus for protecting a structure. The method comprises identifying an exterior shape of the structure; generating a model of a mask based on the exterior shape of the structure; and forming the mask using a three dimensional printer based on the model.

BACKGROUND INFORMATION

1. Field

The present disclosure relates generally to manufacturing assembliesand, in particular, to protecting structures while manufacturingassemblies. Still more particularly, the present disclosure relates to amethod and apparatus for forming masks used to protect structures duringpainting.

2. Background

In manufacturing assemblies, various types of coatings may be applied todifferent structures on the assembly. For example, without limitation,these coatings may be selected from at least one of a sealant, anadhesive, a primer, an optical coating, a corrosive-resistant coating, alacquer, paint, or other suitable types of coatings.

These coatings may provide the structures with desired characteristicsfor the performance of the assembly. As an example, skin panels thatform portions of a platform may be painted.

When applying paint to a structure in the assembly, a sprayer may beused to apply the paint. Care may need to be taken such that the paintdoes not overspray in an undesired manner onto other structures of theassembly.

In some cases, protective material may be placed over various structuresprior to painting to protect the structures from unintended contact withthe paint. This protective material may take the form of a maskingmaterial. The masking material may be secured to the surface of thestructure such that movement of the masking material is reduced duringpainting.

The application of the masking material, however, may take more timethan desired. In addition, the masking material may not protect thestructure in a desired manner. As a result, the time needed tomanufacture the assembly, including rework to remove overspray, may takemore time than desired. Accordingly, it is desirable to have a methodand system that take into account one or more of the issues discussedabove as well as other possible issues.

SUMMARY

An illustrative embodiment of the present disclosure provides a methodfor protecting a structure. The method may comprise identifying anexterior shape of the structure. The method may also generate a model ofa mask based on the exterior shape of the structure. The method may alsoform the mask using a three-dimensional printer based on the model.

A further illustrative embodiment of the present disclosure provides amethod for protecting a structure. The method may comprise identifying asurface of the structure from a model of the structure. The method mayalso generate a model of a mask based on the surface of the structure.Generating the model of the mask may comprise generating an interiorsurface substantially the same shape as the surface of the structure andgenerating a handle. The method may also form the mask using athree-dimensional printer based on the model. The method may furtherplace the mask over the structure. The method may also adhere a base ofthe mask to a base of the structure by applying tape to a first surfaceof the mask and a second surface of the base.

Another illustrative embodiment of the present disclosure provides asystem. The system comprises computer-aided design software, additivemanufacturing equipment, and a mask. The computer-aided design softwaregenerates a model of the mask based on a model of a surface of astructure to be masked. The additive manufacturing equipment forms themask based on the model of the mask. The mask comprises a plurality oflayers forming a hollow body with an interior surface that has asubstantially similar shape to an exterior shape of the structure to bemasked, an integral base, and an integral handle.

The features and functions can be achieved independently in variousembodiments of the present disclosure or may be combined in yet otherembodiments in which further details can be seen with reference to thefollowing description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features believed characteristic of the illustrativeembodiments are set forth in the appended claims. The illustrativeembodiments, however, as well as a preferred mode of use, furtherobjectives and features thereof, will best be understood by reference tothe following detailed description of an illustrative embodiment of thepresent disclosure when read in conjunction with the accompanyingdrawings, wherein:

FIG. 1 is an illustration of an aircraft in accordance with anillustrative embodiment;

FIG. 2 is an illustration of a block diagram of a manufacturingenvironment in accordance with an illustrative embodiment;

FIG. 3 is an illustration of an aircraft structure over which a mask maybe desirable in accordance with an illustrative embodiment;

FIG. 4 is an illustration of a mask and a structure in accordance withan illustrative embodiment;

FIG. 5 is an illustration of an aircraft structure overlaid by a mask inaccordance with an illustrative embodiment;

FIG. 6 is an illustration of a cross-sectional view of an aircraftstructure overlaid by a mask in accordance with an illustrativeembodiment;

FIG. 7 is an illustration of a flowchart of a process for protecting astructure in accordance with an illustrative embodiment;

FIG. 8 is an illustration of a flowchart of a process for protecting astructure in accordance with an illustrative embodiment;

FIG. 9 is an illustration of a block diagram of an aircraftmanufacturing and service method in accordance with an illustrativeembodiment;

FIG. 10 is an illustration of a block diagram of an aircraft in which anillustrative embodiment may be implemented; and

FIG. 11 is an illustration of a block diagram of a data processingsystem in accordance with an illustrative embodiment.

DETAILED DESCRIPTION

The illustrative embodiments recognize and take into account one or moredifferent considerations. For example, the illustrative embodimentsrecognize and take into account that it may be desirable to have aprotective material for protecting structures during finishingprocesses. This protective material may take the form of a mask. Forexample, without limitation, the illustrative embodiments recognize andtake into account that having a mask may increase the level ofprotection from overspray of paint or other coating material duringmanufacturing. In this illustrative example, “overspray” refers to theapplication of material, such as paint, onto an unintended location.

The illustrative embodiments further recognize and take into accountthat it may be desirable to reduce the amount of time needed to applythe protective material to the structure. For example, withoutlimitation, it may take an undesirable amount of time to adheretwo-dimensional sheets to a three-dimensional structure such that asurface of the three-dimensional structure is sufficiently covered. Asan example, it may take an undesirable amount of time to adhere sheetsof paper to an aircraft antenna prior to a finishing process.

The illustrative embodiments thus recognize and take into account thatit may be desirable to form a mask that is three dimensional. Further,the illustrative embodiments also recognize and take into account thatit may be desirable to form a mask that has an interior surface having asubstantially similar shape to an exterior shape of a structure.

The illustrative embodiments also recognize and take into account thatit may be desirable for a mask to have a designated location foradhering the mask to the structure. By having a designated location foradhering the mask to the structure, manufacturing time may be reduced.

The illustrative embodiments further recognize and take into accountthat the surface of the structure may have a finished surface. Theillustrative embodiments recognize and take into account that contactwith another object may undesirably impact the finished surface of thestructure. Thus, the illustrative embodiments recognize and take intoaccount that it may be desirable for a mask not to touch the finishedsurface. Moreover, the illustrative embodiments recognize and take intoaccount that it may be desirable to reuse a mask, such that a singlemask may be used to protect more than one structure. Thus, theillustrative embodiments may provide a method and apparatus forprotecting a structure.

With reference now to the figures, and in particular, with reference toFIG. 1, an illustration of an aircraft is depicted in which anillustrative embodiment may be implemented. In this illustrativeexample, aircraft 100 has wing 102 and wing 104 attached to body 106.Aircraft 100 includes engine 108 attached to wing 102 and engine 110attached to wing 104.

Body 106 has tail section 112. Horizontal stabilizer 114, horizontalstabilizer 116, and vertical stabilizer 118 are attached to tail section112 of body 106.

Aircraft 100 is an example of an aircraft having a structure which maybe masked from a finishing process using a protective covering inaccordance with an illustrative embodiment. For example, antenna 120attached to body 106 may be masked during a finishing process for body106 of aircraft 100. Further, a mask may be used to cover a structureassociated with wing 102 or wing 104 during assembly and manufacturing.A protective covering is removed prior to use of aircraft 100.

This illustration of aircraft 100 is provided for purposes ofillustrating one environment in which the different illustrativeembodiments may be implemented. The illustration of aircraft 100 in FIG.1 is not meant to imply architectural limitations as to the manner inwhich different illustrative embodiments may be implemented. Forexample, aircraft 100 is shown as a commercial passenger aircraft. Thedifferent illustrative embodiments may be applied to other types ofaircraft, such as private passenger aircraft, a rotorcraft, and othersuitable type of aircraft.

Turning now to FIG. 2, an illustration of a block diagram of amanufacturing environment is depicted in accordance with an illustrativeembodiment. In this depicted example, manufacturing environment 200 maybe an area in which finishing process 202 may be applied to aircraft204.

In this illustrative example, finishing process 202 may be a coatingprocess applied to aircraft 204. The coating may take a number ofdifferent forms in this illustrative example. For example, withoutlimitation, the coating applied by finishing process 202 may take theform of at least one of a sealant, an adhesive, a primer, an opticalcoating, a corrosive-resistant coating, a lacquer, paint, or othersuitable types of coatings. In this illustrative example, the coatingmay take the form of paint 205.

As used herein, the phrase “at least one of,” when used with a list ofitems, means different combinations of one or more of the listed itemsmay be used and only one of the items in the list may be needed. Theitem may be a particular object, thing, or category. In other words, “atleast one of” means any combination of items or number of items may beused from the list, but not all of the items in the list may berequired.

For example, “at least one of item A, item B, and item C” may mean itemA; item A and item B; item B; item A, item B, and item C; or item B anditem C. In some cases, “at least one of item A, item B, and item C” maymean, for example, without limitation, two of item A, one of item B, andten of item C; four of item B and seven of item C; or some othersuitable combination.

As illustrated, aircraft 204 may include structure 206. Structure 206may be a physical object associated with aircraft 204. Structure 206 maytake various forms in this illustrative example. For example, withoutlimitation, structure 206 may take the form of an antenna, or othersuitable types of structures.

Structure 206 may have base 208 and surface 210. Base 208 may connectstructure 206 to aircraft 204. Surface 210 may be a portion of theoutermost layer of structure 206. In other words, surface 210 may beexposed to the environment around structure 206.

For instance, when structure 206 is an antenna, surface 210 may includesurface 210 of an antenna that extends into the airstream. In anotherillustrative example, when structure 206 is a sensor, structure 206 mayinclude more than one surface that extends into the airstream.

As depicted, surface 210 may have exterior shape 212. Exterior shape 212may be designed to perform functions of structure 206. For example, whenstructure 206 takes the form of an antenna, exterior shape 212 may bedesigned to transmit or receive signals.

It may be desirable to protect surface 210 of structure 206 as paint 205is applied to aircraft 204. In other words, surface 210 may be a portionof aircraft 204 in which paint 205 may not be applied. Mask 214 is athree-dimensional structure that may be used to protect surface 210during painting of aircraft 204. Mask 214 may be a protective coatingfor surface 210 in this illustrative example.

In this depicted example, mask 214 may be used to cover surface 210 ofstructure 206 during the application of paint 205 to aircraft 204. Mask214 may be configured to reduce paint 205 from contacting surface 210 ofstructure 206.

As depicted, mask 214 may be formed of plurality of layers 216.Plurality of layers 216 may be formed of any desirable material such asplaster, metal, metallic alloy, composite, polymeric material 218, orother desirable material. Plurality of layers 216 may be consecutivelylaid down to form mask 214.

Mask 214 may take the form of hollow body 220. Hollow body 220 may beplaced over surface 210 of structure 206 to protect surface 210 frompaint 205 during finishing process 202. Surface 210 may fit withincavity 221 of hollow body 220.

Hollow body 220 may include interior surface 222, base 224, handle 226,first end 228, and second end 230. Interior surface 222 may form cavity221 of hollow body 220. Interior surface 222 may have substantially thesame shape as exterior shape 212 of surface 210. By having substantiallythe same shape as exterior shape 212, interior surface 222 may coversurface 210 without contacting surface 210.

Base 224 may be located at first end 228 of hollow body 220. Base 224may include flange 232. In some illustrative examples, flange 232 mayhave J-shape 234. Flange 232 may aid in removal of mask 214 fromstructure 206 following finishing process 202. Flange 232 may increaseat least one of durability, stability, strength, or other desirableproperty of mask 214.

Flange 232 may aid in adhering mask 214 to structure 206. Flange 232 ofbase 224 may have second surface 236. Second surface 236 may besubstantially flush with first surface 238 of base 208 of structure 206.Adhesive 240 may be placed along first surface 238 and second surface236 to secure mask 214 to structure 206. By placing adhesive 240 alongfirst surface 238 and second surface 236, base 224 of mask 214 may beadhered to base 208 of structure 206. In some illustrative examples,adhesive 240 may take the form of tape 242. In these illustrativeexamples, base 224 of mask 214 may be adhered to base 208 of structure206 by applying tape 242 to first surface 238 of base 208 of structure206 and second surface 236 of base 224 of mask 214.

Base 224 may rest on base 208 of structure 206. In some illustrativeexamples, third surface 244 of base 224 may contact fourth surface 246of structure 206.

Base 224 may be formed of plurality of layers 216. Thus, base 224 may bedescribed as integral to hollow body 220 of mask 214. In someillustrative examples, base 224 may be described as an integral base.

Handle 226 may be located on second end 230 of mask 214. First end 228may be opposite second end 230 of mask 214. Handle 226 may be used forhandling by a human operator. Handle 226 may be used to place mask 214over structure 206. Handle 226 may be used to remove mask 214 fromstructure 206.

Handle 226 may be formed of plurality of layers 216. Thus, handle 226may be described as integral to hollow body 220 of mask 214. In someillustrative examples, handle 226 may be described as an integralhandle.

Manufacturing environment 200 includes equipment to form mask 214. Asdepicted, manufacturing environment 200 includes additive manufacturingequipment 248. Mask 214 may be formed using additive manufacturingequipment 248. Conventional machining processes may form structures byremoving material. Additive manufacturing processes form structures byadding material.

Specifically, additive manufacturing processes may form structures byadding consecutive and discrete layers. Additive manufacturing may allowon-demand manufacture of desired parts.

Additive manufacturing equipment 248 may take the form ofthree-dimensional printer 250 or any other desirable additivemanufacturing equipment. In one illustrative example, additivemanufacturing equipment 248 may form mask 214 by sequentially formingplurality of layers 216. The thickness of each of plurality of layers216 may depend on the resolution of additive manufacturing equipment248. Additive manufacturing equipment 248 may form mask 214 frommaterial 252. Material 252 may take the form of at least one of aplaster, a metal, a metallic alloy, a composite, a polymeric material,or other desirable material. In some illustrative examples, material 252may be polymeric material 218.

By forming mask 214 using additive manufacturing equipment 248, mask 214may be manufactured in a desirable amount of time. Specifically, mask214 may be formed in-house rather than having to purchase or request amask. Purchasing or requesting a mask may have an undesirable amount ofshipping or processing times. Further, forming mask 214 using additivemanufacturing equipment 248 may have lower manufacturing costs thanconventional masking. Because mask 214 may be manufactured for desirablecosts and in a desirable amount of time, mask 214 may be created for asingle use. In some other illustrative examples, mask 214 may bemanufactured such that mask 214 may be used multiple times.

Three-dimensional printing is an additive process where successivelayers of material are laid down. Three-dimensional printing may beperformed with a variety of different materials such as polymers,plasters, metals, and metal alloys.

Additive manufacturing equipment 248 may be a part of mask formingsystem 254. Mask forming system 254 may also include database 256,computer-aided design software 258, controller 260, and inspectionequipment 262.

As depicted, additive manufacturing equipment 248, such asthree-dimensional printer 250, may be used to form mask 214 based onthree-dimensional model 264 of structure 206 stored in database 256. Inthis illustrative example, database 256 may be a storage deviceconfigured to store models such as three-dimensional model 264.

In some illustrative examples, three-dimensional model 264 may be a datafile used to generate representations 266 of structure 206. In someillustrative examples, three-dimensional model 264 may be used to formstructure 206. In some illustrative examples, three-dimensional model264 may be a data file formed using data taken from an inspection ofstructure 206 by inspection equipment 262. Three-dimensional model 264of surface 210 of structure 206 to be masked may be a model of exteriorshape 212 of an aircraft antenna.

Representations 266 may be views of structure 206 based on variousinputs. For instance, representations 266 may be generated based oninput from operator 268, model 270, input from another source, or othersuitable inputs. Operator 268 may be a human operator in thisillustrative example.

Representations 266 may take the form of a three-dimensionalrepresentation, a two-dimensional representation, or some other type ofrepresentation. Representations 266 may be modified, analyzed, or bothusing computer-aided design software 258.

In this depicted example, computer-aided design software 258 may be acomputer program implemented within computer system 272. In thisillustrative example, computer system 272 may include one or morecomputers. When more than one computer is present in computer system272, those computers are in communication with each other via acommunications medium such as a network.

Computer system 272 may include display device 274 in this illustrativeexample. Display device 274 may be hardware configured to presentrepresentations 266 of structure 206 to operator 268. Display device 274may be selected from at least one of a touch screen, a computer monitor,a mobile device, a laptop, an electronic reader, a projector, or someother type of display device.

As illustrated, computer-aided design software 258 may be selected fromvarious types of software. For example, without limitation,computer-aided design software 258 may be selected from at least one ofAutoCAD, Autodesk, CATIA, Pro/Engineer, SolidWorks, Unigraphics, orother suitable types of computer-aided design software.

In this depicted example, computer-aided design software 258 may beconfigured to retrieve three-dimensional model 264 of structure 206 fromdatabase 256. From three-dimensional model 264, computer-aided designsoftware 258 may then identify surface 210 of structure 206 to becovered by mask 214. Specifically, computer-aided design software 258may identify surface 276 which may be a representation of surface 210 ofstructure 206.

As illustrated, once surface 210 of structure 206 that is to be coveredby mask 214 is identified, computer-aided design software 258 maygenerate three-dimensional model 278 of mask 214 based on surface 210.In some illustrative examples, three-dimensional model 278 of mask 214may be generated based on exterior shape 212 of structure 206.Three-dimensional model 278 may be generated based on three-dimensionalmodel 264. However, three-dimensional model 278 may have features notpresent in three-dimensional model 264. For example, three-dimensionalmodel 278 may be formed by adding a handle not present in exterior shape212 of surface 210. As another example, three-dimensional model 278 maybe formed by adding a J-shaped flange not present in exterior shape 212of surface 210.

As illustrated, controller 260 may be a device configured to generateinstructions 279 for additive manufacturing equipment 248 based onthree-dimensional model 278 such that additive manufacturing equipment248 forms mask 214 in a desired manner. In this illustrative example,controller 260 may be implemented in software, hardware, firmware, or acombination thereof. When software is used, the operations performed bycontroller 260 may be implemented using, for example, withoutlimitation, program code configured to run on a processor unit. Whenfirmware is used, the operations performed by controller 260 may beimplemented using, for example, without limitation, program code anddata and stored in persistent memory to run on a processor unit.

When hardware is employed, the hardware may include one or more circuitsthat operate to perform the operations performed by controller 260.Depending on the implementation, the hardware may take the form of acircuit system, an integrated circuit, an application-specificintegrated circuit (ASIC), a programmable logic device, or some othersuitable type of hardware device configured to perform any number ofoperations.

A programmable logic device may be configured to perform certainoperations. The device may be permanently configured to perform theseoperations or may be reconfigurable. A programmable logic device maytake the form of, for example, without limitation, a programmable logicarray, a programmable array logic, a field programmable logic array, afield programmable gate array, or some other type of programmablehardware device.

In some illustrative examples, the operations, processes or bothperformed by controller 260 may be performed using organic componentsintegrated with inorganic components. In some cases, the operations,processes, or both may be performed by entirely of organic components,excluding a human being. As one illustrative example, circuits inorganic semiconductors may be used to perform these operations,processes, or both. In this illustrative example, controller 260 may beimplemented in computer system 272. In other illustrative examples,controller 260 may be remote to computer system 272.

As depicted, instructions 279 may be commands executable by additivemanufacturing equipment 248. Controller 260 may generate instructions279 in format 280 usable for additive manufacturing equipment 248.Instructions 279 may then be sent to additive manufacturing equipment248 in format 280 such that additive manufacturing equipment 248 mayform mask 214 from material 252. Instructions 279 may be sent toadditive manufacturing equipment 248 via wireless communications links,wired communications links, another suitable type of communicationsmedium, or a combination thereof.

The illustration of manufacturing environment 200, and morespecifically, of mask 214 and mask forming system 254 and the componentswithin mask forming system 254 in FIG. 2, is not meant to imply physicalor architectural limitations to the manner in which an illustrativeembodiment may be implemented. Other components in addition to or inplace of the ones illustrated may be used. Some components may beoptional. Also, the blocks are presented to illustrate some functionalcomponents. One or more of these blocks may be combined, divided, orcombined and divided into different blocks when implemented in anillustrative embodiment.

Turning now to FIG. 3, an illustration of an aircraft structure overwhich a mask may be desirable is depicted in accordance with anillustrative embodiment. Structure 300 may be a physical implementationof structure 206 of FIG. 2. Structure 300 may take the form of antenna302. Antenna 302 may be a representation of antenna 120 of FIG. 1.Antenna 302 has surface 304 which may be masked during finishingprocesses such as painting. Surface 304 may have finishing 306 which maybe removed, marred, or otherwise undesirably affected by itemscontacting finishing 306. Antenna 302 may also have base 308. Antenna302 may be connected to an aircraft such as aircraft 100 by base 308.

Turning now to FIG. 4, an illustration of a mask and a structure isdepicted in accordance with an illustrative embodiment. Mask 400 may bea physical implementation of mask 214 of FIG. 2. Mask 400 may be used tocover surface 304 of antenna 302 prior to a finishing process. Mask 400may be formed of a plurality of layers of material using an additivemanufacturing process.

Mask 400 may take the form of hollow body 402 which is shown beingplaced over antenna 302. Mask 400 may have integral base 404 located atfirst end 406 of mask 400. Mask 400 may have integral handle 408 locatedat second end 410 of mask 400. Integral handle 408 may be used toposition mask 400 over antenna 302.

Turning now to FIG. 5, an illustration of an aircraft structure overlaidby a mask is depicted in accordance with an illustrative embodiment.View 500 is a view of mask 400 positioned over antenna 302 such thatmask 400 covers surface 304 shown in FIG. 3. As can be seen in view 500,integral base 404 of mask 400 contacts base 308 of antenna 302. Further,base 308 has first surface 502 which is substantially flush with secondsurface 504 of integral base 404. To secure mask 400 to antenna 302, anadhesive may be placed on at least a portion of first surface 502 andsecond surface 504. In some illustrative examples, tape may be adheredto first surface 502 and second surface 504.

Turning now to FIG. 6, an illustration of a cross-sectional view of anaircraft structure overlaid by a mask is depicted in accordance with anillustrative embodiment. View 600 may be a view of mask 400 and antenna302 along cross-section 6-6 of FIG. 5.

As depicted in view 600, integral base 404 may include flange 602 havingJ-shape 604. Flange 602 may be secured to base 308 of antenna 302 usingadhesive 606. In view 600, adhesive 606 takes the form of tape 608. Tape608 may be applied over surface 504 and surface 502. Mask 400 and tape608 may protect antenna 302 from overspray. Tape 608 may protect surface502 from overspray. Tape 608 may be added in one step. Tape 608 may beremoved in one step.

The illustrations of structure 300 and mask 400 in FIGS. 3-6 are notmeant to imply physical or architectural limitations to the manner inwhich an illustrative embodiment may be implemented. Other components inaddition to or in place of the ones illustrated may be used. Somecomponents may be optional.

The different components shown in FIGS. 1 and 3-6 may be illustrativeexamples of how components shown in block form in FIG. 2 can beimplemented as physical structures. Additionally, some of the componentsin FIGS. 1 and 3-6 may be combined with components in FIG. 2, used withcomponents in FIG. 2, or a combination of the two.

Turning now to FIG. 7, an illustration of a flowchart of a process forprotecting a structure is depicted in accordance with an illustrativeembodiment. Process 700 may be used to protect structure 206 duringfinishing process 202 of FIG. 2. Process 700 may also be used to formmask 214 of FIG. 2.

Process 700 may identify an exterior shape of the structure (operation702). The structure may be a structure to be masked during a finishingprocess. The structure may be a structure having a surface to beprotected during painting. In some illustrative examples, the structuremay be an antenna.

Process 700 may also generate a model of a mask based on the exteriorshape of the structure (operation 704). The model of the mask may begenerated such that the mask may cover the structure. The model of themask may include features not present in the structure.

Process 700 may also form the mask using a three-dimensional printerbased on the model (operation 706). Afterwards, the process terminates.

Turning now to FIG. 8, an illustration of a flowchart of a process forprotecting a structure is depicted in accordance with an illustrativeembodiment. Process 800 may be used to protect structure 206 duringfinishing process 202 of FIG. 2. Process 800 may also be used to formmask 214 of FIG. 2.

Process 800 may identify a surface of the structure from a model of thestructure (operation 802). The model of the structure may be a modelused to form the structure. The model of the structure may be formedfrom data created during inspection of the structure. The surface may bea surface which may be protected from unintended contact with paint.

Process 800 may also generate a model of a mask based on the surface ofthe structure (operation 804). Generating the model of the mask maycomprise generating an interior surface substantially the same shape asthe surface of the structure, and generating a handle. The model may bea three-dimensional model of the mask. The model may include featureswhich are not present in the structure. The handle may be one example ofsuch a feature. Another feature not present in the structure may be aJ-shaped flange.

Process 800 may also form the mask using a three-dimensional printerbased on the model (operation 806). The three-dimensional printer maylay a plurality of layers of material to form the mask. Forming the maskmay include forming a hollow body, forming an integral base, and formingan integral handle. In some illustrative examples, the three-dimensionalprinter may form the mask of a thermoplastic material.

Process 800 may further place the mask over the structure (operation808). The mask may be placed such that the structure is positionedwithin a cavity formed by a hollow body of the mask. Placing the maskover the structure may include placing the mask over the structure suchthat the mask only contacts a base of the structure.

Process 800 may also adhere a base of the mask to a base of thestructure by applying tape to a first surface of the mask and a secondsurface of the base (operation 810). The first surface of the mask andthe second surface of the base may be substantially flush. Afterwards,the process terminates.

The flowcharts and block diagrams in the different depicted embodimentsillustrate the architecture, functionality, and operation of somepossible implementations of apparatuses and methods in an illustrativeembodiment. In this regard, each block in the flowcharts or blockdiagrams may represent at least one of a module, a segment, a function,or a portion or combination thereof of an operation or step.

In some alternative implementations of an illustrative embodiment, thefunction or functions noted in the blocks may occur out of the ordernoted in the figures. For example, in some cases, two blocks shown insuccession may be executed substantially concurrently, or the blocks maysometimes be performed in the reverse order, depending upon thefunctionality involved. Also, other blocks may be added in addition tothe illustrated blocks in a flowchart or block diagram.

For example, process 700 may also place the mask over the structure andadhere a base of the mask to a base of the structure. Adhering the baseof the mask to the base of the structure may include applying tape to afirst surface of the base of the structure and a second surface of thebase of the mask. In some illustrative examples, the first surface andthe second surface are substantially flush. In some illustrativeexamples, the mask only contacts a base of the structure.

In some examples, identifying the exterior shape of the structurecomprises identifying a surface of the structure from a model of thestructure. The model may be a three-dimensional model used to form thestructure. In some illustrative examples, the model may be formed fromdata created by an inspection of the structure.

Process 700 may also protect the surface of the structure using the maskduring a finishing process. The surface of the structure may beprotected by placing the mask over the structure such that the interiorsurface of the mask does not contact the surface of the structure.

In some illustrative examples, in process 700, generating a model of amask based on the exterior shape of the structure forms an interiorsurface having a substantially similar shape to the exterior shape ofthe structure. In some illustrative examples, in process 700, generatinga model of the mask based on the exterior shape of the structure furthercomprises adding a handle not present in the exterior shape of thestructure to the model of the mask. In some illustrative examples, inprocess 700, generating a model of the mask based on the exterior shapeof the structure further comprises adding a J-shaped flange not presentin the exterior shape of the structure to the model of the mask.

Illustrative embodiments of the present disclosure may be described inthe context of aircraft manufacturing and service method 900 as shown inFIG. 9 and aircraft 1000 as shown in FIG. 10. Turning first to FIG. 9,an illustration of a block diagram of an aircraft manufacturing andservice method is depicted in accordance with an illustrativeembodiment. During pre-production, aircraft manufacturing and servicemethod 900 may include specification and design 902 of aircraft 1000 inFIG. 10 and material procurement 904.

During production, component and subassembly manufacturing 906 andsystem integration 908 of aircraft 1000 in FIG. 10 takes place.Thereafter, aircraft 1000 in FIG. 10 may go through certification anddelivery 910 in order to be placed in service 912. While in service 912by a customer, aircraft 1000 in FIG. 10 is scheduled for routinemaintenance and service 914, which may include modification,reconfiguration, refurbishment, and other maintenance or service.

Each of the processes of aircraft manufacturing and service method 900may be performed or carried out by a system integrator, a third party,an operator, or a combination thereof. In these examples, the operatormay be a customer. For the purposes of this description, a systemintegrator may include, without limitation, any number of aircraftmanufacturers and major-system subcontractors; a third party mayinclude, without limitation, any number of vendors, subcontractors, andsuppliers; and an operator may be an airline, a leasing company, amilitary entity, a service organization, and so on.

With reference now to FIG. 10, an illustration of a block diagram of anaircraft is depicted in which an illustrative embodiment may beimplemented. In this example, aircraft 1000 is produced by aircraftmanufacturing and service method 900 in FIG. 9 and may include airframe1002 with plurality of systems 1004 and interior 1006. Examples ofsystems 1004 include one or more of propulsion system 1008, electricalsystem 1010, hydraulic system 1012, and environmental system 1014. Anynumber of other systems may be included. Although an aerospace exampleis shown, different illustrative embodiments may be applied to otherindustries, such as the automotive industry.

Apparatuses and methods embodied herein may be employed during at leastone of the stages of aircraft manufacturing and service method 900 inFIG. 9. In particular, mask 214 may be formed using mask forming system254 from FIG. 2 during any one of the stages of aircraft manufacturingand service method 900. For example, without limitation, mask 214 may beformed during at least one of component and subassembly manufacturing906, system integration 908, routine maintenance and service 914, orsome other stage of aircraft manufacturing and service method 900. Mask214 may then be attached to base 208 of structure 206 in aircraft 204prior to or during manufacturing, rework, or other operations performedduring manufacturing and service method 900.

In one illustrative example, components or subassemblies produced incomponent and subassembly manufacturing 906 in FIG. 9 may be fabricatedor manufactured in a manner similar to components or subassembliesproduced while aircraft 1000 is in service 912 in FIG. 9. As yet anotherexample, one or more apparatus embodiments, method embodiments, or acombination thereof may be utilized during production stages, such ascomponent and subassembly manufacturing 906 and system integration 908in FIG. 9. One or more apparatus embodiments, method embodiments, or acombination thereof may be utilized while aircraft 1000 is in service912, during maintenance and service 914 in FIG. 9, or a combinationthereof. The use of a number of the different illustrative embodimentsmay substantially expedite the assembly, reduce the cost of aircraft1000, or both.

Turning now to FIG. 11, an illustration of a block diagram of a dataprocessing system is depicted in accordance with an illustrativeembodiment. Data processing system 1100 may be used to implement one ormore computers in computer system 158 in FIG. 1. As depicted, dataprocessing system 1100 includes communications framework 1102, whichprovides communications between processor unit 1104, storage devices1106, communications unit 1108, input/output unit 1110, and display1112. In some cases, communications framework 1102 may be implemented asa bus system.

Processor unit 1104 is configured to execute instructions for softwareto perform a number of operations. Processor unit 1104 may comprise anumber of processors, a multi-processor core, some other type ofprocessor, or some combination thereof, depending on the implementation.In some cases, processor unit 1104 may take the form of a hardware unit,such as a circuit system, an application-specific integrated circuit(ASIC), a programmable logic device, or some other suitable type ofhardware unit.

Instructions for the operating system, applications, programs, or bothrun by processor unit 1104 may be located in storage devices 1106.Storage devices 1106 may be in communication with processor unit 1104through communications framework 1102. As used herein, a storage device,also referred to as a computer readable storage device, is any piece ofhardware capable of storing information on a temporary basis, permanentbasis, or both. This information may include, but is not limited to, atleast one of data, program code, or other information.

Memory 1114 and persistent storage 1116 are examples of storage devices1106. Memory 1114 may take the form of, for example, a random accessmemory or some type of volatile or non-volatile storage device.Persistent storage 1116 may comprise any number of components ordevices. For example, persistent storage 1116 may comprise a hard drive,a flash memory, a rewritable optical disk, a rewritable magnetic tape,or some combination of the above. The media used by persistent storage1116 may or may not be removable.

Communications unit 1108 allows data processing system 1100 tocommunicate with other data processing systems, devices, or somecombination thereof. Communications unit 1108 may provide communicationsusing physical communications links, wireless communications links, or acombination thereof.

Input/output unit 1110 allows input to be received from and output to besent to other devices connected to data processing system 1100. Forexample, input/output unit 1110 may allow user input to be receivedthrough at least one of a keyboard, a mouse, or some other type of inputdevice. As another example, input/output unit 1110 may allow output tobe sent to a printer connected to data processing system 1100.

Display 1112 is configured to display information to a user. Display1112 may comprise, for example, without limitation, one of a monitor, atouch screen, a laser display, a holographic display, a virtual displaydevice, or some other type of display device.

In this illustrative example, the processes of the differentillustrative embodiments may be performed by processor unit 1104 usingcomputer-implemented instructions. These instructions may be referred toas program code, computer usable program code, or computer readableprogram code and may be read and executed by one or more processors inprocessor unit 1104.

In these examples, program code 1118 is located in a functional form oncomputer readable media 1120, which is selectively removable, and may beloaded onto or transferred to data processing system 1100 for executionby processor unit 1104. Program code 1118 and computer readable media1120 together form computer program product 1122. In this illustrativeexample, computer readable media 1120 may be computer readable storagemedia 1124 or computer readable signal media 1126.

Computer readable storage media 1124 is a physical or tangible storagedevice used to store program code 1118 rather than a medium thatpropagates or transmits program code 1118. Computer readable storagemedia 1124 may be, for example, without limitation, an optical ormagnetic disk or a persistent storage device that is connected to dataprocessing system 1100.

Alternatively, program code 1118 may be transferred to data processingsystem 1100 using computer readable signal media 1126. Computer readablesignal media 1126 may be, for example, a propagated data signalcontaining program code 1118. This data signal may be an electromagneticsignal, an optical signal, or some other type of signal that can betransmitted over physical communication links, wireless communicationslinks, or some combination thereof.

The illustration of data processing system 1100 in FIG. 11 is not meantto provide architectural limitations to the manner in which theillustrative embodiments may be implemented. The different illustrativeembodiments may be implemented in a data processing system that includescomponents in addition to or in place of those illustrated for dataprocessing system 1100. Further, components shown in FIG. 11 may bevaried from the illustrative examples shown.

Thus, the illustrative embodiments may provide a method and apparatusfor protecting structure 206. A method comprises identifying an exteriorshape of the structure; generating a model of a mask based on theexterior shape of the structure; and forming the mask using athree-dimensional printer based on the model.

By using mask 214 to protect structure 206 in aircraft 204 fromundesired contact with paint 205, structure 206 may be masked morequickly and easily. For example, mask 214 may be formed using additivemanufacturing equipment 248. Mask 214 may be formed based onthree-dimensional model 264 of structure 206. From three-dimensionalmodel 278, mask 214 may be formed with a desired shape. For example,mask 214 may have interior surface 222 that has substantially the sameshape as exterior shape 212 of surface 210. Accordingly, mask 214 maynot undesirably affect surface 210 of structure 206. Specifically, mask214 may not contact surface 210 of structure 206. However, surface 210may be protected from undesired contact with paint 205 by mask 214.

The illustrative embodiments also provide a masking system that may beinstalled more easily than some currently used systems. For instance,mask 214 may be attached to structure 206 in one step. Mask 214 also maybe removed from structure 206 in one step. After removing mask 214 fromstructure 206, mask 214 may be reused over a different structure havingthe same exterior shape as structure 206.

Forming mask 214 in this manner substantially reduces the time neededfor operator 268 to install mask 214. As a result, manufacturing timefor aircraft 204 may be reduced and cost savings may occur.

Yet further, mask 214 may be used on other components other thanaircraft components. Although the illustrative examples for anillustrative embodiment are described with respect to an aircraft, anillustrative embodiment may be applied to other types of platforms. Theplatform may be, for example, a mobile platform, a stationary platform,a land-based structure, an aquatic-based structure, and a space-basedstructure. More specifically, the platform may be a surface ship, atank, a personnel carrier, a train, a spacecraft, a space station, asatellite, a submarine, an automobile, a power plant, a bridge, a dam, ahouse, a manufacturing facility, a building, and other suitableplatforms.

For example, a mask may be created to protect a hood ornament of anautomobile from overspray. As another example, a mask may be created tocover a light on a buoy prior to applying a surface coating.

The description of the different illustrative embodiments has beenpresented for purposes of illustration and description, and is notintended to be exhaustive or limited to the embodiments in the formdisclosed. Many modifications and variations will be apparent to thoseof ordinary skill in the art. Further, different illustrativeembodiments may provide different features as compared to otherdesirable embodiments. The embodiment or embodiments selected are chosenand described in order to best explain the principles of theembodiments, the practical application, and to enable others of ordinaryskill in the art to understand the disclosure for various embodimentswith various modifications as are suited to the particular usecontemplated.

What is claimed is:
 1. A method for protecting a structure, the methodcomprising: identifying an exterior shape of the structure; generating amodel of a mask based on the exterior shape of the structure; andforming the mask using a three dimensional printer based on the model.2. The method of claim 1 further comprising: placing the mask over thestructure; and adhering a base of the mask to a base of the structure.3. The method of claim 2, wherein adhering the base of the mask to thebase of the structure comprises applying tape to a first surface of thebase of the structure and a second surface of the base of the mask. 4.The method of claim 3, wherein the first surface and the second surfaceare substantially flush.
 5. The method of claim 1, wherein identifyingthe exterior shape of the structure comprises identifying a surface ofthe structure from a model of the structure.
 6. The method of claim 5further comprising: protecting the surface of the structure using themask during a finishing process.
 7. The method of claim 1, whereingenerating the model of the mask based on the exterior shape of thestructure forms an interior surface having a substantially similar shapeto the exterior shape of the structure.
 8. The method of claim 1,wherein generating the model of the mask based on the exterior shape ofthe structure further comprises adding a handle not present in theexterior shape of the structure to the model of the mask.
 9. The methodof claim 1, wherein generating the model of the mask based on theexterior shape of the structure further comprises adding a J-shapedflange not present in the exterior shape of the structure to the modelof the mask.
 10. The method of claim 1, wherein the mask only contacts abase of the structure.
 11. The method of claim 1 further comprising:removing the mask from the structure; placing the mask over a secondstructure; and adhering the base of the mask to a base of the secondstructure.
 12. A method for protecting a structure, the methodcomprising: identifying a surface of the structure from a model of thestructure; generating a model of a mask based on the surface of thestructure, wherein generating the model of the mask comprises:generating an interior surface substantially a same shape as the surfaceof the structure; and generating a handle; forming the mask using athree dimensional printer based on the model; placing the mask over thestructure; and adhering a base of the mask to a base of the structure byapplying tape to a first surface of the mask and a second surface of thebase.
 13. The method of claim 12, wherein adhering the base of the maskto the base of the structure by applying tape to the first surface ofthe mask and the second surface of the base, the first surface and thesecond surface are substantially flush.
 14. The method of claim 12,wherein placing the mask over the structure comprises placing the maskover the structure such that the mask only contacts the base of thestructure.
 15. A system comprising: computer-aided design software whichgenerates a model of a mask based on a model of a surface of a structureto be masked; additive manufacturing equipment that forms the mask basedon the model of the mask; and the mask, wherein the mask comprises aplurality of layers forming a hollow body with an interior surface thathas a substantially similar shape to an exterior shape of the structureto be masked; an integral base; and an integral handle.
 16. The systemof claim 15, wherein the plurality of layers are formed of a polymericmaterial.
 17. The system of claim 15, wherein the integral base includesa flange.
 18. The system of claim 17, wherein the flange has a J-shape.19. The system of claim 15, wherein the integral base is located at afirst end of the hollow body and the integral handle is located at anopposite second end of the hollow body.
 20. The system of claim 15,wherein the model of the surface of the structure to be masked is amodel of an exterior shape of an aircraft antenna.